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ExacTech Blast and Paint Processes

ExacTech’s blast and paint processes are driven by the customer’s individual needs. Each job at ExacTech, from the fabrication to final stages, is designed to meet the customer’s exact specifications.

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Prior to paint application, a blasting process takes place. The blasting of the steel uses abrasive and compressed air to remove and clean the surface of any previous paint coating, impurities and abrasive residue. At ExacTech, open air blasting uses compressed air and upper-end abrasive media are used to clean the surface of any potential paint residue, mill scale, corrosion or rust. Cleaning processes range from SSPC-SP6 to SSPC-SP10 standards, set by The Society for Protective Coatings (SSPC). SP6, or commercial blast cleaning, removes all rust, dirt, grease, oil, prior coating, and any other foreign material that is visible to the blaster. The SP6 cleaning process is based on a one-third to two-thirds ratio, where one-third of each square inch can have minimal streaks or stains. SP10 blasting requires a more in-depth clean blast, leaving only 5% of minor streaks and minimal discolorations visible while the remaining 95% are completely free of all other filtrates.

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ExacTech’s skilled team of painters work at military and marine standards with two paint booths measuring 18’ x 55’ and 20’ x 50’10”. The two spray rooms can handle the most complex paint applications.

Current paint coatings being used at ExacTech –

  • epoxy, zinc, waterborne primers
  • urethane, enamels, alkyds, waterborne top coats

Airless and conventional sprayers are used at ExacTech in order to provide various paint spray options when tackling each individual task.

Airless paint sprayers pump paint at extremely high pressures. The paint is sent through a hose and through a tungsten carbide spray tip, in the paint spray gun, creating a broad, fan-shaped pattern of paint to be evenly distributed on the surface. There are many advantages of airless painting, such as a faster paint speed, consistent and high quality finish and the flexibility to paint on a wide range of materials. Larger, less complex surfaces are the best option for airless paint spray procedures.

The conventional spraying process allows for more precise finishes due to the ability to regulate and control output and air pressure. Conventional spraying, also known as pressure pot spraying, is best suited for detail-orientated projects.

Prior to blasting and painting, our painters make sure that ambient and surface temperatures are checked before beginning the process. ExacTech uses a dew point calculation chart to ensure that each blasting and coating application is performed under ideal environmental conditions. Dew point is measured to see if moisture will form on the service. If moisture is present, it can result in rust or residue to form on the surface. ExacTech measures dew point to work efficiently and avoid the need to backtrack and rework the blasting or paint process. After paint completion, product is inspected and dry mil readings are taken and recorded per paint manufacturer’s recommendations.

In addition to the painting and assembly processes, ExacTech offers a number of turnkey capabilities that continue to exceed customer expectations. ExacTech’s cost effective processing and precision machining ensure the highest quality while cutting down on project overhead and expediting the entire fabrication process.

 

 

Picking the Right Wire for the Job

ExacTech’s high-quality, precision fabrication is a result of nearly 25+ years of highly-experienced fabrication, machining and assembly that provides customers with a world-class turnkey operation. Since there is no wire that classifies as “one-size-fits-all,” ExacTech offers various wire options in order to provide only the best for our customers. Each wire has a unique job and reflects both the quality and durability needed for every individual task.

ExacTech’s Four In-House Wires

The four specific ExacTech in-house wires consist of a 1/16 flux-core, a 3/32 flux-core, 1/8 submerged-arc wire, and a .052 metal core. 1/16 wire is utilized during applications needing both in and out position welding, allowing for good deposition rates. The 3/32 flux-core wire is used for some finishing passes and the filling of large bevels. The 1/8 sub-arc wire is used at ExacTech to weld flange plates together. The metal core .052 wire is primarily used to weld small parts, such as wheel frames to provide useful productivity.

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When and How to Use Flux-Core vs. Metal Core Wire

Flux-core and solid metal core wires provide the perfect balance when tackling each unique welding project in a time-efficient manner. Welders should take into consideration the proper shielding gas, voltage settings, thickness of material, and the location/atmosphere in which they are welding. These factors help determine which wire should be used for each specific project.

Flux-core wires contain their own shielding method, increasing the weld mobility. The shielding carbon dioxide gas allows for the electrode weld to be protected from oxygen, nitrogen and moisture in the air. Carbon dioxide flows through the welding gun, allowing a temporary gas bubble to form around the electrode for the duration of the weld. Pure CO2 gas has an easier ionization potential, higher thermal conductivity and is more reactive in comparison to using a combination of CO2 and argon gas which produces higher oxidization levels in the arc.

Metal-core wires operate using a spray transfer mode, producing a broad, cone-shape arc resulting in a wide penetration profile. Metal core wires have high deposition rates and efficiencies, high duty cycles, high travel speeds, and low splatter levels. The .052 wire does not need a constant voltage power supply in order to operate, resulting in a much cleaner welding process. The inside of metal core wires contain metallic fillers and arc stabilizers that provide multiple benefits to the final weld, such as creating high impact strengths and reducing pre-welding activities through easy, consistent arc control.

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Sub-arc Wire Welding

At ExaTech, welding with submerged arc wire allows for a clean and consistent weld for all large beam fabrication projects. The first step to sub-arcing is to fit-up the flange plate and then by filling the machine one-half to three-fourths full with .052 metal core. Sub-arc welding requires the wire to be continuously-fed through the tractor sub-arc machine for the weld duration, resulting in a smooth and constant end result.

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The wire options utilized at ExacTech allow our welders to fabricate in the most practical manner on the market. The flux-core and solid metal core wires have different properties and are designed for various projects and environments. Sub-arc wire welding allows for a consistent and clean weld for all of our large fabrication projects. At ExacTech, high quality is in our roots, which is why we provide the highest quality wiring materials to meet your specs. Our products are streamlined to deliver high precision throughout the fabrication, machining and assembly processes which is why ExacTech’s wire options are adaptable to fit each unique welding task.

The Benefits of a Consistent and Reliable Quoting Process

The standard request for quotation (RFQ) process is one of the most common practices carried out by any purchasing manager; however, it is a process that often results in extensive turnaround times due to detailed pricing information and other selection criteria.

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With services and goods constantly evolving, it is critical for any organization to prepare and provide a qualified and competitive bid – The metal fabrication process is no exception. At ExacTech Inc., all incoming quotes are reviewed for material, weld, machining, paint, and any secondary requirements such as stress relieving. This assures a consistent, reliable bid day in and day out and an opportunity to gain business while earning the customers’ trust in the process.

Below is an effective step-by-step quoting process that will help assure a consistent and reliable quoting process:

7-Step Quoting Process

  1. To begin the process, all incoming quotes are reviewed for material, welding, machining, paint, and any other secondary requirements that are necessary for the product.
  2. All quotes are entered into a “quote log,” which contains a due date in which we will provide the customer a precise quote.
  3. The material needed for each product is then reviewed for availability. Various departments assess what will be needed and how quickly they can receive the required supplies. By carrying out this process, ExacTech can ensure that all necessary materials will be available from the beginning stages to the final product.
  4. We review the customer’s due date once again in order to ensure that the due date can be met after consideration.
  5. ExacTech provides a quote for machining hours, tooling and material requirements, outside services, and the allotted fabrication hours.
  6. The quote is then assembled and reviewed for accuracy prior to submitting to our customers. At ExacTech we review every fabrication process multiple times before sending a final quote to ensure our estimate is as precise as it possibly could be!
  7. The quote is submitted to the customer for review and consideration. ExacTech will initiate a follow-up call for any questions or concerns the customer may have regarding the estimate.

At ExacTech, we take great pride in meeting and exceeding our customer’s strictest quality and delivery requirements. Follow this 7-step process to see how ExacTech is the perfect fit for all your turnkey solutions.

Nessinger Promotion Helps to Move Brand Forward

Nessinger Promotion Helps to Move Brand Forward 

STURGEON BAY, WI (March 9th, 2017) – ExacTech Inc. has recently announced the promotion of Jason Nessinger to General Manager. Nessinger started with ExacTech as a fabricator/welder in 2005 and has used his hands on experience, combined with a number of certificates from the Wisconsin School of Business, to continuously expand his role within the company.

Nessinger currently oversees the entire ExacTech operation and has played a critical role in both the installation of the lean manufacturing process and the expansion of production capacity through the investment in heavy equipment.  Through years of partnering with a variety of industries, Jason has developed the sales expertise and knowledge to execute best practices for creating maximum customer value.

ExacTech Inc. continues to position itself as a leader in mid to mega sized projects with innovative equipment and an extremely diverse workforce. This wide range of capabilities has attracted a broad range of new customers and has kept existing customers coming back with advanced opportunities. To learn more about the continuous innovations happening at ExacTech Inc., visit the company overview video here.

Through quality production and remarkable lead times, ExacTech continues to exceed expectations. To learn more about ExacTech Inc.’s custom metal fabrication capabilities, visit www.exactechinc.com and follow on LinkedIn and Facebook.

On the cutting edge of contemporary machine centers, ExacTech Inc. is a world-class, turnkey metalworking operation that handles medium-to-heavy metal fabrication, ultra-precision CNC machining, burning, blasting, metal assembly and finishing services. Located in Wisconsin, ExacTech’ s state-of-the-art metal and fabrication outsourcing facility serves customers throughout the continental United States, in Canada and overseas, and it has developed a solid reputation for high quality and precision tolerance work.

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A Checklist: Benefits of Fabrication Projects Under One Roof

December 08, 2016

Today we turn our attention to the ability of your steel fabrication partner to complete an entire project in a single location. Partnering with a turnkey metal operation that meets capacity, lead time, and quality standards will have some serious benefits, but how can you make sure that they are checking all the boxes? In order to correctly choose the right business partner, take a look at the key services that are needed to keep all of your projects under one roof.

Custom FabricationA Checklist- Custom FabricationBurning and Lifting Abilities, Various Welding Techniques

 Precision Machining

   A Checklist- Precision Maching

    Custom Projects, Design, Various Operational Envelopes

Finishing Solutions

 A Checklist- Finishing Solutions

Paint, Metal Finishing, Assembly

 You may or may not use all of the available processes of your business partner, but custom, or niche, projects may require different services. Partnering with a turnkey steel fabrication company will ensure that all needs are properly addressed. There is also the benefit of reduced costs, as efficiency increases from the start of a project through to the end.

Advice…

Make sure that your current partner isn’t relying on several other locations to complete the key services above. If the result is any of these services being contracted out to other locations, it is likely you are not receiving the most efficient solution to meet your needs and that partner is not in control of their own schedule. Check to make sure that all of your parts are being fabricated and machined in the same location, because if they aren’t you are probably paying for it.